Model year record

2004 Volvo S40

6 recall campaigns on file for this model year. 75 owner complaints on file.

Recalls

Recall campaignNHTSA 10V566000

Equipment: electrical: navigational system(global positioning system)

Component
Equipment: electrical: navigational system(global positioning system)
Manufacturer
VOLVO CARS OF N.A. LLC.
Vehicles affected
416
Reported to NHTSA
2010-11-08
Owners notified
2010-11-18

Defect description

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Safety risk

AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

Manufacturer remedy

VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.

Recall campaignNHTSA 08V033000

Fuel system, gasoline: delivery: fuel pump

Component
Fuel system, gasoline: delivery: fuel pump
Manufacturer
VOLVO CARS OF N.A. LLC.
Vehicles affected
23,000
Reported to NHTSA
2008-01-28
Owners notified
2008-02-20

Defect description

ON CERTAIN VEHICLES SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA, REOCCURRING, LONG-TERM EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS SUCH AS SALTY-WET CONDITIONS, IT IS POSSIBLE FOR THE PUMP ELECTRONIC MODULE (PEM) TO BECOME CORRODED INTERNALLY. THIS CAN CAUSE A FAULTY SIGNAL TO THE FUEL PUMP, RESULTING IN LOW OR NO FUEL PRESSURE TO THE ENGINE.

Safety risk

IF THIS OCCURS, THE CHECK ENGINE LIGHT MAY ILLUMINATE. IN SOME CASES, THE VEHICLE MAY FAIL TO START OR MAY STALL, INCREASING THE RISK OF A CRASH.

Manufacturer remedy

DEALERS WILL REPLACE THE PEM AND INSTALL IT IN A NEW LOCATION TO PREVENT CORROSION. THE RECALL BEGAN ON FEBRUARY 20, 2008. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

Recall campaignNHTSA 06V137000

Fuel system, gasoline

Component
Fuel system, gasoline
Manufacturer
VOLVO CARS OF N.A. LLC.
Vehicles affected
16,175
Reported to NHTSA
2006-04-24
Owners notified
2006-06-05

Defect description

ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH T5 TURBO ENGINES, THE POLYAMIDE TUBE IN THE FUEL LINE IS SENSITIVE TO THE EXTREME TEMPERATURES THAT MAY OCCUR IN THE AREA WHERE THE TURBO/EXHAUST MANIFOLD IS LOCATED.

Safety risk

THIS MAY POTENTIALLY RESULT IN FUEL LINE LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Manufacturer remedy

DEALERS WILL CHANGE THE FUEL LINE MATERIAL TO TEFLON FREE OF CHARGE. THE RECALL BEGAN ON JUNE 5, 2006. OWNERS MAY CONTACT VOLVO CARS AT 1-800-458-1552.

Recall campaignNHTSA 04V493000

Service brakes, hydraulic: power assist: vacuum: hoses, lines/piping, and fittings

Component
Service brakes, hydraulic: power assist: vacuum: hoses, lines/piping, and fittings
Manufacturer
VOLVO CARS OF N.A. LLC.
Vehicles affected
1,719
Reported to NHTSA
2004-10-14
Owners notified
2004-11-29

Defect description

ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.

Safety risk

IF THIS OCCURS, MORE BRAKE PEDAL FORCE MAY BE REQUIRED TO STOP THE VEHICLE AND/OR MAY EXPERIENCE A ROUGH ENGINE IDLE, WHICH COULD RESULT IN A CRASH.

Manufacturer remedy

DEALERS WILL INSPECT, AND IF NECESSARY, REPLACE THE VACUUM HOSE. THE RECALL BEGAN ON NOVEMBER 29, 2004. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.

Recall campaignNHTSA 03V424000

Fuel system, gasoline

Component
Fuel system, gasoline
Manufacturer
VOLVO CARS OF N.A. LLC.
Vehicles affected
15,067
Reported to NHTSA
2003-10-24
Owners notified
2004-01-28

Defect description

ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.

Safety risk

FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.

Manufacturer remedy

DEALERS WILL INSTALL A V-CLAMP TO THE FUEL RAIL. OWNER NOTIFICATION BEGAN ON JANUARY 28, 2004. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.

Recall campaignNHTSA 03V284000

Equipment: other: labels

Component
Equipment: other: labels
Manufacturer
VOLVO CARS OF N.A. LLC.
Vehicles affected
220,407
Reported to NHTSA
2003-08-01
Owners notified
2003-12-19

Defect description

CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE SECOND ISOFIX GUIDE WAS NOT INSTALLED IN THESE VEHICLES AND, IN CERTAIN CASES, THE OWNER'S MANUAL ISOFIX INFORMATION IS INCORRECT.

Safety risk

THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.

Manufacturer remedy

OWNERS WILL RECEIVE A LETTER/PACKAGE CONSISTING OF THE SECOND ISOFIX GUIDE WITH INSTALLATION INSTRUCTIONS, AND IN CERTAIN CASES, THE CORRECTED OWNER'S MANUAL MAY BE PROVIDED. IF THE OWNER WANTS TO TAKE THEIR VEHICLE TO A VOLVO DEALER FOR INSTALLATION OF THE GUIDE, IT WILL BE PERFORMED AT NO CHARGE TO THE OWNER. OWNER NOTIFICATION BEGAN ON DECEMBER 19, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.

Owner complaints

A complaint is one person's report to a federal agency. It is not a finding.

ComponentComplaintsMedian mileage
Electrical system929,500 mi
Air bags689,000 mi
Service brakes, hydraulic445,000 mi
Air bags: frontal340,000 mi
Electrical system: instrument cluster/panel325,000 mi
Engine and engine cooling: engine348,000 mi
Fuel system, gasoline364,000 mi
Service brakes342,000 mi
Steering325,000 mi
Vehicle speed control337,171 mi
Air bags: frontal: sensor/control module210,000 mi
Engine2100,625 mi
Engine and engine cooling236,000 mi
Exterior lighting2140,000 mi
Fuel system, gasoline: delivery: fuel pump295,000 mi
Fuel/propulsion system2104,000 mi
Service brakes, hydraulic: pedals and linkages220 mi
Unknown or other252,500 mi
Electrical system: 12V/24V/48V battery1
Equipment: appliance: air conditioner1
Forward collision avoidance: warnings1123,713 mi
Fuel system, other: storage: fuel gauge system1
Latches/locks/linkages110,000 mi
Latches/locks/linkages: doors: latch1
Power train1
Service brakes, air: antilock119,215 mi
Service brakes, hydraulic: foundation components1
Service brakes, hydraulic: power assist: hydraulic: hoses, lines/piping, and fittings113,400 mi
Steering: rack and pinion118,971 mi
Structure: body197,000 mi
Structure: body: trunk lid1
Suspension1
Tires1145,000 mi
Vehicle speed control: accelerator pedal1
Visibility: power window devices and controls1
Visibility: windshield wiper/washer110,000 mi
Visibility: windshield wiper/washer: motor1

The 2003 model has 3 times as many complaints as this one. The 2005 model has roughly the same number of complaints as this one. These figures reflect raw complaint counts, not failure rates. Higher-selling model years naturally receive more complaints.

Safety recall repairs are provided free of charge by franchised dealers, regardless of vehicle age or mileage. This page displays aggregated data for the model year. To check recall status for a specific vehicle, search its VIN at nhtsa.gov.